1104D Mechanical

Transient Performance Characteristics

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Introduction
The 1104D Mechanical represents a significant achievement in providing our customers with a minimum-impact route to Tier 3 compliance and provides a market-leading level of power density & performance. However, Tier 3 emissions limits in this power range are significantly tighter than at Tier 2 and this effectively limits the range of possible adjustment to optimise engine performance. Customers are likely to identify some changes in the response characteristics of the engine, when compared to a comparable Tier 2 model. In many cases, these changes will be insignificant, or may be overcome by finetuning of the installation/ driveline; in other cases, the customer requirements may be more effectively satisfied through the selection of a different engine configuration.This presentation is the front piece to a package of information that sets out to:

Reinforce the positioning of the 1104D Mechanical product within the range; Define areas where customers might see a change in machine operating characteristics; Identify areas where compensating adjustments could be made to machines; Provide guidance as to the sensitivity of various application types to these issues; Suggest the most suitable engine configuration for specific customer sensitivities

The objective is to ensure that the customer has enough information to make an informed selection of the most appropriate engine configuration for the application.

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Presentation Overview

Section 1: 1104D Product Positioning Customer Expectations at Stage IIIA/ Tier 3 Section 2: What is Transient Response? 1104D Transient Characteristics

Section 3: IPSD Journey to Stage IIIA/ Tier 3 Mechanical Section 4: Selling the transient message

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Section 1

Product Positioning at Stage IIIA/ Tier 3

Selling the Range
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Section Agenda

Tier 3 Product Positioning Overview Electronic Positioning

Mechanical Positioning

Customer Expectations at Stage IIIA/ Tier 3

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Tier 3 Product Positioning Overview

Transient concerns (smoke & response) can be avoided by selecting the right product for the application

Strong 4.4L product range at Stage IIIA/ Tier 3 Electronic & Mechanical offering Power range overlap Unique sales propositions
Mechanical offering = Minimal change Electronic offering = Optimum Stage IIIA/ Tier 3 performance Mechanical product offers significant commercial benefits but wont provide the performance benefits of the Electronic product

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Electronic Positioning

Utilises proven components of Caterpillar ACERT technology Common rail fuel system

Smart wastegate turbocharger

Performance optimised across the load and speed range Optimised SFC

Minimised heat rejection

Electronic Control means Optimum Tier 3 Performance

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Mechanical Positioning

Design goal to maintain as close to Stage II/ Tier 2 performance with minimal external changes Development focus on internal improvements: Combustion chamber Air system (camshaft & cylinder head) Fuel Injection

Cooling system

Mechanical Control means Minimum Change from Tier 2 Ease of Changeover

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Mechanical Positioning

Package virtually identical to Tier 2 & Tier 0 Identical major hook-up points Minimal visible external changes Common front and rear ends Many components carried over (95%) Product reliability Minimised additional parts inventory Streamlined training Consistent serviceability Low OEM investment costs

Minimised engineering costs

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Customer Expectations at Tier 3

The next generation is always better The engine will be more responsive at Tier 3 The engine will have less visible smoke at Tier 3 General Customer Expectations: Driveability = Tier 2 or better Smoke = Less visible smoke Power/ Torque = Tier 2 or better Fuel Consumption = Minimal change Package Size = Drop-in solution General Performance = Improvements

In reality, achieving a Mechanical offering at Stage IIIA/ Tier 3 results in some compromises (especially levels of visible smoke and low speed response)
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Section 2

1104D Mechanical
Transient Response Characteristics
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Section Agenda

Transient Performance Overview What is Transient Response? 1104D Mechanical Transient Response Characteristics Load Acceptance from Low Idle Loaded Acceleration from Low Idle

Acceleration from a Loaded Condition Free Acceleration Smoke (FAS) Loaded Acceleration Smoke

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Transient Performance Overview

Emissions Challenge was significant for Mechanical products at Stage IIIA/ Tier 3

Challenge is shared by the competition Transient characteristics are different at Stage IIIA/ Tier 3 due to the technologies employed to achieve emissions legislation

Customer Management Understand the transient characteristics of the 1104D Manage customer expectations accordingly Match the right product to the right application Utilise the full product range, it is a key strength!

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What is Transient Response?

Responsiveness of the Machine Load acceptance from low idle How the engine responds when applying sudden load Loaded acceleration from low idle How the machine performs accelerating from a standing start Acceleration from a loaded condition How the machine feels accelerating through the speed range Smoke Free Acceleration Smoke (FAS) Level of black smoke when blipping the throttle from idle with the machine in neutral and any PTO unloaded Loaded Acceleration Smoke Level of black smoke generated during acceleration with the machine loaded
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1) Load Acceptance from Low Idle

How the engine responds when applying sudden load? Load Acceptance from Low Idle degradation from equivalent Stage II/ Tier 2 model 1104D-44: -10% 1104D-44T: -20% 1104D-44TA: -10% The trade-off between low speed, un-boosted torque and Free Acceleration Smoke (FAS) has been optimised for all ratings by the Engineering team at IPSD Customers can increase low idle speed, or rematch machine transmission and hydraulic demands, to further improve performance

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2) Loaded Acceleration from Low Idle

How the machine feels to the operator when accelerating from a standing start with a heavy load?

Loaded Acceptance from Low Idle degradation from Tier 2 1104D-44NA: -10% 1104D-44T: Dependent on machine loading characteristics 1104D-44TA: Dependent on machine loading characteristics
Atmospheric Boost Control (ABC) will improve performance IPSD offers two variants of low pressure options to best match to application Customers can increase low idle speed, or rematch machine transmission and hydraulic demands, to further improve performance

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3) Acceleration from a Loaded Condition

How the machine feels to the operator when accelerating through the speed range? 1104D will achieve boosted fuel at lower manifold pressure than the 1104C Stage II/ Tier 2 range The product will feel more responsive in many circumstances Naturally Aspirated product (1104D-44) will see a degradation of around 10% compared to Stage II/ Tier 2

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4) Free Acceleration Smoke (FAS)

Level of black smoke when blipping the throttle from idle with the machine in neutral and any PTOs unloaded? FAS will be higher than 1104C but within legislation requirements (including Switzerland & Austria) There will be visible black smoke at Stage IIIA/ Tier 3 Mechanical Smoke acceptability is highly subjective Manage customer expectations relative to Stage II/ Tier 2 product Certain markets will be more sensitive to smoke than others The trade-off between low speed, un-boosted torque and Free Acceleration Smoke (FAS) has been optimised for all ratings by the Engineering team at IPSD

Customer improvements can be made by optimising drive train inertias and managing engine acceleration

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5) Loaded Acceleration Smoke

Level of black smoke generated during acceleration with the machine loaded?

Loaded Acceleration Smoke will be higher than 1104C

Smoke levels are highly subjective and will need to be assessed at the customer level

Flag the issue to Applications if The customer is in a highly smoke sensitive market (e.g. Scandinavia) The environment the machine is operating in requires no visible smoke (e.g. indoor) The machine will be performing a lot of complex operations (e.g. Shovel Loader)
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Section 3

IPSD Journey to Tier 3 Mechanical

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Section Agenda

Emissions Technology Choices IPSD Tier 3 Solution Performance Comparison: Tier 2 to Tier 3 1104D Mechanical Performance

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Tier 3 Emissions Challenge

Experience from on-highway development shows that Tier 3 levels of NOx would typically require Electronic FIE strategies. Some engine manufacturers have achieved Tier 3 levels with rotary mechanical FIE, using innovative technological approaches. IPSD will offer a full range of mechanical products between 54.5 and 83kW, from NA to TA to meet the needs of each customer.

Heavy-Duty Diesel NOx-PM Trade-Off By Technologies and Legislation

Tier 3 Off-Highway <75kW

Needham, J., 1991. "Engine Experience and EPA Regulations", University of Minnesota Short Course Diesel Particulate Matter, October 1991

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Technology Options at Tier 3 Mechanical

Air System Charge-Air Cooling Variable Geometry Turbo (VGT) Fuel System Multi-Shot Injection Injection Rate Shape Injection Retard Combustion System Re-Entrant Piston Bowl Quiescent Combustion (with highpressure FIE) Optimised port swirl General Reduce Engine Parasitics Optimise Torque Curve Shape

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IPSD Stage IIIA/ Tier 3 Solution

IPSD has achieved Tier 3 emissions standards with minimal customer impact and maximum carry over of todays proven design by innovative development of: Air system strategies FIE Combustion chamber FIE boost control
1104D-44TA 68 83kW Turbo After-Cooled Mechanical Rotary FIP Rising Rate Injection Dynamic AFR Control * Re-Entrant Piston Hi-Efficiency Water Pump

SFC, heat rejection, and transient response trade-off optimised

1104D-44T 55 75kW Straight Turbo Mechanical Rotary FIP Rising Rate Injection Dynamic AFR Control * Re-Entrant Piston Hi-Efficiency Water Pump 1104D-44 54 56kW Naturally Mechanical Rotary FIP Rising Rate Injection Re-Entrant Piston Hi-Efficiency Water Pump
* Patents applied for

Engine Rating Aspiration FIE

Combustion General

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Performance Comparison: Tier 2 to Tier 3

400 380

360

Tier 2 Tier 3

Full-load torque curves are similar for Tier 2 and Tier 3 ratings However, un-boosted torque is lower on Tier 3 due to emissions control strategies
The penalties of low unboosted torque have been offset to some extent by management of fuelling control to transition to fully-boosted torque at lower speed

Torque [Nm]

340 320 300 280 260 240 220 200 800 1000 1200 1400 1600 1800 2000 2200

Engine Speed [rpm]

Tier 3 Concerns: Low-speed load acceptance Acceleration from low idle Operating close to smoke limit

Tier 3 Strengths: Competitive mechanical strategy More responsive from part load than Tier 2 More lugging capability than Tier 2

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1104D Mechanical Performance

1104D Mechanical versus 1104C BSFC Heat Rejection Noise Altitude +5% +5% -1 dBA 3000 m Tier 3 Market Standard versus Tier 2 Market Standard + 5 to +10 % + 5 to +10 % 3000m

Oil Change
Load Acceptance (from low idle)

250 to 500 hrs

TA Turbo 10% 20%

250 to 500 hrs

-10 to -25%

Performance Features: BSFC and heat rejection believed to be highly competitive Noise reduction over Stage II/ Tier 2 will be noticeable Load acceptance and response believed to be competitive Reliability and durability as Stage II/ Tier 2 Industrial Power Systems Division
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Section 4

Selling Transient Messaging

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Section Agenda

Competitive Landscape Transient Sales Messaging Transient Response Practical Approach What should I be doing?

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Competitive Landscape

Competition will have a similar, or greater, challenge with Transient Performance at Stage IIIA/ Tier 3

Technology choices are the same for all competitors marketing Mechanical product

Cummins QSB 3.3 Reduced displacement 4 Cylinder engine Expect Load Acceptance from Low Idle degradation from Stage II/ Tier 2 of around 25% Competition using for example AVL TINER system Expect Load Acceptance from Low Idle degradation from Tier 2 of around 10% to 25%

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Transient Sales Messaging

Product Benefits Competitive Mechanical Product Strategy

Product Sensitivities Low Speed Load Acceptance

Strong Sales Proposition Strong Steady State Performance Responsiveness from Part Load same or better than Stage II/ Tier 2 Lugging Capability same or better than Stage II/ Tier 2

Acceleration from Low Idle Transient Smoke

Product sensitivities are application dependent. Selection of the right product, and managing customer expectations, is the key to avoiding transient issues

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Assessment of Transient Acceptability

Transient acceptability is largely subjective. The following criteria should be considered in relation to a specific customer requirement: Level of transient operation Customer brand proposition Sensitivity to visible smoke
Score 1 2 3 4 5 Level of Transient Operation Constant Speed Lugging / Roading Shuttling / Pull-Away Digging Loading Premium Machine Indoor / Warehouse Mid-Range Machine Construction Site Customer Brand Proposition Value Machine Environmental Sensitivity to Smoke Outside / Ag Typical Machine Pump set Ag Tractor FLT Telehandler / BHL Wheeled Loader

This information is graphically represented on the next slide.

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Engine Selection: Practical Approach

5
4 3 2 1
1104D Mechanical 1104D Electronic

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What should I be doing?

Determine if any of your customers are sensitive to smoke or response based on territory and application Make customers aware that the transient characteristics of the 1104D are different from Stage II/ Tier 2 Manage customer expectations accordingly Smoke, although highly subjective, is worse than Stage II/ Tier 2 Machine responsiveness will be different at Stage IIIA/ Tier 3

Sell the strong product benefits, there is a positive side to the transient story Steady state performance has improved over Stage II/ Tier 2 Product is more responsive from part load Product has additional lugging capability Strong position vs. other mechanical offerings in the marketplace

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Summary

1104D Mechanical is a highly competitive product with a strong sales proposition

Transient concerns can be avoided by matching the engine to the application/ transmission and by managing customer expectations relative to Stage II/ Tier 2
Transient response characteristics of the 1104D are part of the Stage IIIA/ Tier 3 Mechanical story for all suppliers in the industry selling Mechanical product Applications Teams have been briefed on 1104D Transient characteristics. Please contact your Applications Engineer if you have any questions or concerns

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